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Abstract:

Fibrous structures that exhibit a Tensile Ratio of greater than 0.5 as
measured according to the Tensile Strength Test Method described herein
and a Geometric Mean Flexural Rigidity (GM Flexural Rigidity or GM Flex)
of less than 195 mg*cm2/cm as measured according to the Flexural
Rigidity Test Method described herein and/or a Geometric Mean Modulus (GM
Modulus) of less than 935 g/cm and/or a Machine Direction Modulus (MD
Modulus) of less than 845 g/cm, are provided.

Claims:

1. A single-ply, embossed fibrous structure that exhibits a Tensile Ratio
of greater than 0.5 to less than 1.75 as measured according to the
Tensile Strength Test Method and a GM Flexural Rigidity of less than 195
mg*cm2/cm as measured according to the Flexural Rigidity Test
Method.

6. A single-ply, through-air-dried, embossed fibrous structure that
exhibits a Tensile Ratio of greater than 0.5 as measured according to the
Tensile Strength Test Method and a GM Flexural Rigidity of less than 56
mg*cm2/cm as measured according to the Flexural Rigidity Test
Method.

10. A fibrous structure that exhibits a Tensile Ratio of greater than
1.33 to less than 1.75 as measured according to the Tensile Strength Test
Method and a GM Flexural Rigidity of less than 70 mg*cm2/cm as
measured according to the Flexural Rigidity Test Method.

12. The fibrous structure according to claim 10 wherein the fibrous
structure is an embossed fibrous structure.

13. The fibrous structure according to claim 10 wherein the fibrous
structure is an uncreped fibrous structure.

14. The fibrous structure according to claim 10 wherein the fibrous
structure is a sanitary tissue product.

15. A single-ply, embossed fibrous structure that exhibits a Tensile
Ratio of greater than 0.5 as measured according to the Tensile Strength
Test Method and a GM Modulus of less than 935 g/cm as measured according
to the Modulus Test Method.

20. A fibrous structure that exhibits a Tensile Ratio of greater than
1.33 to less than 1.8 as measured according to the Tensile Strength Test
Method and a GM Modulus of less than 935 g/cm as measured according to
the Modulus Test Method.

22. The fibrous structure according to claim 20 wherein the fibrous
structure is an uncreped fibrous structure.

23. The fibrous structure according to claim 20 wherein the fibrous
structure is a sanitary tissue product.

24. A single-ply, embossed fibrous structure that exhibits a Tensile
Ratio of greater than 0.5 as measured according to the Tensile Strength
Test Method and a MD Modulus of less than 845 g/cm as measured according
to the Modulus Test Method.

29. A fibrous structure that exhibits a Tensile Ratio of greater than
1.33 to less than 1.80 as measured according to the Tensile Strength Test
Method and a MD Modulus of less than 845 g/cm as measured according to
the Modulus Test Method.

31. The fibrous structure according to claim 29 wherein the fibrous
structure is a through-air-dried, single-ply, embossed fibrous structure.

32. The fibrous structure according to claim 29 wherein the fibrous
structure is an uncreped fibrous structure.

33. The fibrous structure according to claim 29 wherein the fibrous
structure is a sanitary tissue product.

34. A single-ply, embossed fibrous structure that exhibits a Tensile
Ratio of greater than 0.5 to less than 1.75 as measured according to the
Tensile Strength Test Method and a CD Modulus of less than 980 g/cm as
measured according to the Modulus Test Method.

44. An embossed fibrous structure that exhibits a Tensile Ratio of
greater than 0.5 to less than 1.75 as measured according to the Tensile
Strength Test Method and a CD Modulus of less than 1560 g/cm as measured
according to the Modulus Test Method.

Description:

FIELD OF THE INVENTION

[0001] The present invention relates to fibrous structures that exhibit a
Tensile Ratio of greater than 0.5 as measured according to the Tensile
Strength Test Method described herein and a Geometric Mean Flexural
Rigidity (GM Flexural Rigidity or GM Flex) of less than 195
mg*cm2/cm as measured according to the Flexural Rigidity Test Method
described herein and/or a Geometric Mean Modulus (GM Modulus) of less
than 935 g/cm and/or a Machine Direction Modulus (MD Modulus) of less
than 845 g/cm. The modulus values are measured according to the Modulus
Test Method described herein.

BACKGROUND OF THE INVENTION

[0002] Fibrous structures, particularly sanitary tissue products
comprising fibrous structures, are known to exhibit different values for
particular properties. These differences may translate into one fibrous
structure being softer or stronger or more absorbent or more flexible or
less flexible or exhibit greater stretch or exhibit less stretch, for
example, as compared to another fibrous structure.

[0003] One property of fibrous structures that is desirable to consumers
is the Tensile Ratio of the fibrous structure. It has been found that at
least some consumers desire fibrous structures that exhibit a Tensile
Ratio of greater than 0.5 as measured according to the Tensile Strength
Test Method.

[0004] Accordingly, there exists a need for fibrous structure that
exhibits a Tensile Ratio of greater than 0.5 as measured according to the
Tensile Strength Test Method.

SUMMARY OF THE INVENTION

[0005] The present invention fulfills the needs described above by
providing a fibrous structure that exhibits a Tensile Ratio of greater
than 0.5 as measured according to the Tensile Strength Test Method.

[0006] In one example of the present invention, a single-ply, embossed
fibrous structure that exhibits a Tensile Ratio of greater than 0.5 to
less than 1.75 and a GM Flexural Rigidity of less than 195
mg*cm2/cm, is provided.

[0007] In another example of the present invention, a single-ply,
through-air-dried, embossed fibrous structure that exhibits a Tensile
Ratio of greater than 0.5 and a GM Flexural Rigidity of less than 56
mg*cm2/cm, is provided.

[0008] In even another example of the present invention, a fibrous
structure that exhibits a Tensile Ratio of greater than 1.33 to less than
1.75 and a GM Flexural Rigidity of less than 70 mg*cm2/cm, is
provided.

[0009] In still another example of the present invention, a single-ply,
embossed fibrous structure that exhibits a Tensile Ratio of greater than
0.5 and a GM Modulus of less than 935 g/cm, is provided.

[0010] In even still another example of the present invention, a fibrous
structure that exhibits a Tensile Ratio of greater than 1.33 to less than
1.80 and a GM Modulus of less than 935 g/cm, is provided.

[0011] In even yet another example of the present invention, a single-ply,
embossed fibrous structure that exhibits a Tensile Ratio of greater than
0.5 and a MD Modulus of less than 845 g/cm, is provided.

[0012] In still yet another example of the present invention, a fibrous
structure that exhibits a Tensile Ratio of greater than 1.33 to less than
1.80 and a MD Modulus of less than 845 g/cm, is provided.

[0013] In even still yet another example of the present invention, a
fibrous structure that exhibits a Tensile Ratio of greater than 0.5 to
less than 1.75 and a CD Modulus of less than 980 g/cm, is provided.

[0014] In still yet another example of the present invention, a
single-ply, embossed fibrous structure that exhibits a Tensile Ratio of
greater than 1.2 to less than 1.75, is provided.

[0015] In yet another example of the present invention, an embossed
fibrous structure that exhibits a Tensile Ratio of greater than 0.5 to
less than 1.75 and a CD Modulus of less than 1560 g/cm, is provided.

[0016] Accordingly, the present invention provides fibrous structures that
exhibit a Tensile Ratio of greater than 0.5 and a GM Flexural Rigidity of
less than 195 mg*cm2/cm and/or a GM Modulus of less than 935 g/cm
and/or a MD Modulus of less than 845 g/cm.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] FIG. 1 is a plot of GM Flexural Rigidity (GM Flex) to Tensile Ratio
for fibrous structures of the present invention and commercially
available fibrous structures, both single-ply and multiply, embossed and
unembossed sanitary tissue products, illustrating the relatively low
level of GM Flexural Rigidity exhibited by the fibrous structures of the
present invention;

[0018] FIG. 2 is a plot of GM Modulus to Tensile Ratio for fibrous
structures of the present invention and commercially available fibrous
structures, both single-ply and multi-ply sanitary tissue products,
illustrating the relatively low level of GM Modulus exhibited by the
fibrous structures of the present invention;

[0019]FIG. 3 is a plot of MD Modulus to Tensile Ratio for fibrous
structures of the present invention and commercially available fibrous
structures, both single-ply and multi-ply, embossed and unembossed
sanitary tissue products, illustrating the relatively low level of MD
Modulus exhibited by the fibrous structures of the present invention;

[0020] FIG. 4 is a plot of CD Modulus to Tensile Ratio for fibrous
structures of the present invention and commercially available fibrous
structures, both single-ply and multi-ply sanitary tissue products,
illustrating the relatively low level of CD Modulus exhibited by the
fibrous structures of the present invention;

[0021] FIG. 5 is a schematic representation of an example of a fibrous
structure in accordance with the present invention;

[0022] FIG. 6 is a cross-sectional view of FIG. 5 taken along line 6-6;

[0024] FIG. 8 is an electromicrograph of a portion of a prior art fibrous
structure;

[0025] FIG. 9 is a schematic representation of an example of a fibrous
structure according to the present invention;

[0026] FIG. 10 is a cross-section view of FIG. 9 taken along line 10-10;

[0027] FIG. 11 is a schematic representation of an example of a fibrous
structure according to the present invention;

[0028] FIG. 12 is a schematic representation of an example of a fibrous
structure according to the present invention;

[0029]FIG. 13 is a schematic representation of an example of a fibrous
structure according to the present invention;

[0030]FIG. 14 is a schematic representation of an example of a fibrous
structure comprising various forms of linear elements in accordance with
the present invention;

[0031]FIG. 15 is a schematic representation of an example of a method for
making a fibrous structure according to the present invention;

[0032]FIG. 16 is a schematic representation a portion of an example of a
molding member in according with the present invention;

[0033] FIG. 17 is a cross-section view of FIG. 16 taken along line 17-17.

DETAILED DESCRIPTION OF THE INVENTION

Definitions

[0034] "Fibrous structure" as used herein means a structure that comprises
one or more filaments and/or fibers. In one example, a fibrous structure
according to the present invention means an orderly arrangement of
filaments and/or fibers within a structure in order to perform a
function. Non-limiting examples of fibrous structures of the present
invention include paper, fabrics (including woven, knitted, and
non-woven), and absorbent pads (for example for diapers or feminine
hygiene products).

[0035] Non-limiting examples of processes for making fibrous structures
include known wet-laid papermaking processes and air-laid papermaking
processes. Such processes typically include steps of preparing a fiber
composition in the form of a suspension in a medium, either wet, more
specifically aqueous medium, or dry, more specifically gaseous, i.e. with
air as medium. The aqueous medium used for wet-laid processes is
oftentimes referred to as a fiber slurry. The fibrous slurry is then used
to deposit a plurality of fibers onto a forming wire or belt such that an
embryonic fibrous structure is formed, after which drying and/or bonding
the fibers together results in a fibrous structure. Further processing
the fibrous structure may be carried out such that a finished fibrous
structure is formed. For example, in typical papermaking processes, the
finished fibrous structure is the fibrous structure that is wound on the
reel at the end of papermaking, and may subsequently be converted into a
finished product, e.g. a sanitary tissue product.

[0036] The fibrous structures of the present invention may be homogeneous
or may be layered. If layered, the fibrous structures may comprise at
least two and/or at least three and/or at least four and/or at least five
layers.

[0037] The fibrous structures of the present invention may be co-formed
fibrous structures.

[0038] "Co-formed fibrous structure" as used herein means that the fibrous
structure comprises a mixture of at least two different materials wherein
at least one of the materials comprises a filament, such as a
polypropylene filament, and at least one other material, different from
the first material, comprises a solid additive, such as a fiber and/or a
particulate. In one example, a co-formed fibrous structure comprises
solid additives, such as fibers, such as wood pulp fibers, and filaments,
such as polypropylene filaments.

[0039] "Solid additive" as used herein means a fiber and/or a particulate.

[0040] "Particulate" as used herein means a granular substance or powder.

[0041] "Fiber" and/or "Filament" as used herein means an elongate
particulate having an apparent length greatly exceeding its apparent
width, i.e. a length to diameter ratio of at least about 10. In one
example, a "fiber" is an elongate particulate as described above that
exhibits a length of less than 5.08 cm (2 in.) and a "filament" is an
elongate particulate as described above that exhibits a length of greater
than or equal to 5.08 cm (2 in.).

[0042] Fibers are typically considered discontinuous in nature.
Non-limiting examples of fibers include wood pulp fibers and synthetic
staple fibers such as polyester fibers.

[0043] Filaments are typically considered continuous or substantially
continuous in nature. Filaments are relatively longer than fibers.
Non-limiting examples of filaments include meltblown and/or spunbond
filaments. Non-limiting examples of materials that can be spun into
filaments include natural polymers, such as starch, starch derivatives,
cellulose and cellulose derivatives, hemicellulose, hemicellulose
derivatives, and synthetic polymers including, but not limited to
polyvinyl alcohol filaments and/or polyvinyl alcohol derivative
filaments, and thermoplastic polymer filaments, such as polyesters,
nylons, polyolefins such as polypropylene filaments, polyethylene
filaments, and biodegradable or compostable thermoplastic fibers such as
polylactic acid filaments, polyhydroxyalkanoate filaments and
polycaprolactone filaments. The filaments may be monocomponent or
multicomponent, such as bicomponent filaments.

[0044] In one example of the present invention, "fiber" refers to
papermaking fibers. Papermaking fibers useful in the present invention
include cellulosic fibers commonly known as wood pulp fibers. Applicable
wood pulps include chemical pulps, such as Kraft, sulfite, and sulfate
pulps, as well as mechanical pulps including, for example, groundwood,
thermomechanical pulp and chemically modified thermomechanical pulp.
Chemical pulps, however, may be preferred since they impart a superior
tactile sense of softness to tissue sheets made therefrom. Pulps derived
from both deciduous trees (hereinafter, also referred to as "hardwood")
and coniferous trees (hereinafter, also referred to as "softwood") may be
utilized. The hardwood and softwood fibers can be blended, or
alternatively, can be deposited in layers to provide a stratified web.
U.S. Pat. No. 4,300,981 and U.S. Pat. No. 3,994,771 are incorporated
herein by reference for the purpose of disclosing layering of hardwood
and softwood fibers. Also applicable to the present invention are fibers
derived from recycled paper, which may contain any or all of the above
categories as well as other non-fibrous materials such as fillers and
adhesives used to facilitate the original papermaking. Non-limiting
examples of suitable hardwood pulp fibers include eucalyptus and acacia.
Non-limiting examples of suitable softwood pulp fibers include Southern
Softwood Kraft (SSK) and Northern Softwood Kraft (NSK).

[0045] In addition to the various wood pulp fibers, other cellulosic
fibers such as cotton linters, rayon, lyocell and bagasse can be used in
this invention. Other sources of cellulose in the form of fibers or
capable of being spun into fibers include grasses and grain sources.

[0046] In addition, trichomes such as from "lamb's ear" plants and seed
hairs can also be utilized in the fibrous structures of the present
invention.

[0047] "Sanitary tissue product" as used herein means a soft, low density
(i.e. < about 0.15 g/cm3) web useful as a wiping implement for
post-urinary and post-bowel movement cleaning (toilet tissue), for
otorhinolaryngological discharges (facial tissue), and multi-functional
absorbent and cleaning uses (absorbent towels). The sanitary tissue
product may be convolutedly wound upon itself about a core or without a
core to form a sanitary tissue product roll.

[0048] In one example, the sanitary tissue product of the present
invention comprises a fibrous structure according to the present
invention.

[0050] In one example, the sanitary tissue product, for example a
single-ply, through-air-dried, embossed sanitary tissue product, exhibits
a Total Dry Tensile of less than about 1875 g/76.2 mm and/or less than
1850 g/76.2 mm and/or less than 1800 g/76.2 mm and/or less than 1700
g/76.2 mm and/or less than 1600 g/76.2 mm and/or less than 1560 g/76.2 mm
and/or less than 1500 g/76.2 mm to about 450 g/76.2 mm and/or to about
600 g/76.2 mm and/or to about 800 g/76.2 mm and/or to about 1000 g/76.2
mm.

[0051] In yet another example, the sanitary tissue product, for example a
single-ply, embossed sanitary tissue product, exhibits a Total Dry
Tensile of less than about 1560 g/76.2 mm and/or less than 1500 g/76.2 mm
and/or less than 1400 g/76.2 mm and/or less than 1300 g/76.2 mm and/or to
about 450 g/76.2 mm and/or to about 600 g/76.2 mm and/or to about 800
g/76.2 mm and/or to about 1000 g/76.2 mm.

[0052] The sanitary tissue products of the present invention may exhibit
an initial total wet tensile strength of less than 600 g/76.2 mm00 g/in)
and/or less than 450 g/76.2 mm and/or less than 300 g/76.2 mm and/or less
than about 225 g/76.2 mm.

[0053] The sanitary tissue products of the present invention may exhibit a
density (measured at 95 g/in2) of less than about 0.60 g/cm3
and/or less than about 0.30 g/cm3 and/or less than about 0.20
g/cm3 and/or less than about 0.10 g/cm3 and/or less than about
0.07 g/cm3 and/or less than about 0.05 g/cm3 and/or from about
0.01 g/cm3 to about 0.20 g/cm3 and/or from about 0.02
g/cm3 to about 0.10 g/cm3.

[0054] The sanitary tissue products of the present invention may be in the
form of sanitary tissue product rolls. Such sanitary tissue product rolls
may comprise a plurality of connected, but perforated sheets of fibrous
structure, that are separably dispensable from adjacent sheets.

[0056] "Weight average molecular weight" as used herein means the weight
average molecular weight as determined using gel permeation
chromatography according to the protocol found in Colloids and Surfaces
A. Physico Chemical & Engineering Aspects, Vol. 162, 2000, pg. 107-121.

[0057] "Basis Weight" as used herein is the weight per unit area of a
sample reported in lbs/3000 ft2 or g/m2 and is measured
according to the Basis Weight Test Method described herein.

[0058] "Caliper" as used herein means the macroscopic thickness of a
fibrous structure. Caliper is measured according to the Caliper Test
Method described herein.

[0059] "Bulk" as used herein is calculated as the quotient of the Caliper,
expressed in microns, divided by the Basis Weight, expressed in grams per
square meter. The resulting Bulk is expressed as cubic centimeters per
gram. For the products of this invention, Bulks can be greater than about
3 cm3/g and/or greater than about 6 cm3/g and/or greater than
about 9 cm3/g and/or greater than about 10.5 cm3/g up to about
30 cm3/g and/or up to about 20 cm3/g. The products of this
invention derive the Bulks referred to above from the basesheet, which is
the sheet produced by the tissue machine without post treatments such as
embossing. Nevertheless, the basesheets of this invention can be embossed
to produce even greater bulk or aesthetics, if desired, or they can
remain unembossed. In addition, the basesheets of this invention can be
calendered to improve smoothness or decrease the Bulk if desired or
necessary to meet existing product specifications.

[0060] "Density" as used herein is calculated as the quotient of the Basis
Weight expressed in grams per square meter divided by the Caliper
expressed in microns. The resulting Density is expressed as grams per
cubic centimeters (g/cm3 or g/cc). In one example, the Densities can
be greater than 0.05 g/cm3 and/or greater than 0.06 g/cm3
and/or greater than 0.07 g/cm3 and/or less than 0.10 g/cm3
and/or less than 0.09 g/cm3 and/or less than 0.08 g/cm3. In one
example, a fibrous structure of the present invention exhibits a density
of from about 0.055 g/cm3 to about 0.095 g/cm3.

[0061] "Basis Weight Ratio" as used herein is the ratio of low basis
weight portion of a fibrous structure to a high basis weight portion of a
fibrous structure. In one example, the fibrous structures of the present
invention exhibit a basis weight ratio of from about 0.02 to about 1. In
another example, the basis weight ratio of the basis weight of a linear
element of a fibrous structure to another portion of a fibrous structure
of the present invention is from about 0.02 to about 1.

[0062] "Tensile Ratio" as used herein is determined as described in the
Tensile Strength Test Method described herein.

[0063] "GM Flexural Rigidity" as used herein is determined as described in
the Flexural Rigidity Test Method described herein.

[0064] "MD Modulus" as used herein is determined as described in the
Modulus Test Method described herein.

[0065] "CD Modulus" as used herein is determined as described in the
Modulus Test Method described herein.

[0066] "Machine Direction" or "MD" as used herein means the direction
parallel to the flow of the fibrous structure through the fibrous
structure making machine and/or sanitary tissue product manufacturing
equipment.

[0067] "Cross Machine Direction" or "CD" as used herein means the
direction parallel to the width of the fibrous structure making machine
and/or sanitary tissue product manufacturing equipment and perpendicular
to the machine direction.

[0069] "Plies" as used herein means two or more individual, integral
fibrous structures disposed in a substantially contiguous, face-to-face
relationship with one another, forming a multi-ply fibrous structure
and/or multi-ply sanitary tissue product. It is also contemplated that an
individual, integral fibrous structure can effectively form a multi-ply
fibrous structure, for example, by being folded on itself.

[0070] "Linear element" as used herein means a discrete, unidirectional,
uninterrupted portion of a fibrous structure having length of greater
than about 4.5 mm. In one example, a linear element may comprise a
plurality of non-linear elements. In one example, a linear element in
accordance with the present invention is water-resistant. Unless
otherwise stated, the linear elements of the present invention are
present on a surface of a fibrous structure. The length and/or width
and/or height of the linear element and/or linear element forming
component within a molding member, which results in a linear element
within a fibrous structure, is measured by the Dimensions of Linear
Element/Linear Element Forming Component Test Method described herein.

[0071] In one example, the linear element and/or linear element forming
component is continuous or substantially continuous with a useable
fibrous structure, for example in one case one or more 11 cm×11 cm
sheets of fibrous structure.

[0072] "Discrete" as it refers to a linear element means that a linear
element has at least one immediate adjacent region of the fibrous
structure that is different from the linear element.

[0073] "Unidirectional" as it refers to a linear element means that along
the length of the linear element, the linear element does not exhibit a
directional vector that contradicts the linear element's major
directional vector.

[0074] "Uninterrupted" as it refers to a linear element means that a
linear element does not have a region that is different from the linear
element cutting across the linear element along its length. Undulations
within a linear element such as those resulting from operations such
creping and/or foreshortening are not considered to result in regions
that are different from the linear element and thus do not interrupt the
linear element along its length.

[0075] "Water-resistant" as it refers to a linear element means that a
linear element retains its structure and/or integrity after being
saturated.

[0076] "Substantially machine direction oriented" as it refers to a linear
element means that the total length of the linear element that is
positioned at an angle of greater than 45° to the cross machine
direction is greater than the total length of the linear element that is
positioned at an angle of 45° or less to the cross machine
direction.

[0077] "Substantially cross machine direction oriented" as it refers to a
linear element means that the total length of the linear element that is
positioned at an angle of 45° or greater to the machine direction
is greater than the total length of the linear element that is positioned
at an angle of less than 45° to the machine direction.

[0078] "Embossed" as used herein with respect to a fibrous structure means
a fibrous structure that has been subjected to a process which converts a
smooth surfaced fibrous structure to a decorative surface by replicating
a design on one or more emboss rolls, which form a nip through which the
fibrous structure passes. Embossed does not include creping,
microcreping, printing or other processes that may impart a texture
and/or decorative pattern to a fibrous structure. In one example, the
embossed fibrous structure comprises deep nested embossments that exhibit
an average peak of the embossment to valley of the embossment difference
of greater than 600 μm and/or greater than 700 μm and/or greater
than 800 μm and/or greater than 900 μm as measured using MicroCAD.

Fibrous Structure

[0079] The fibrous structures of the present invention may be a single-ply
or multi-ply fibrous structure.

[0080] In one example of the present invention as shown in FIG. 1, a
single-ply, embossed fibrous structure exhibits a Tensile Ratio of
greater than 0.5 and/or greater than 1 and/or greater than 1.33 and/or
less than 1.75 and/or less than 1.65 and/or less than 1.55 and a GM
Flexural Rigidity of less than 195 mg*cm2/cm and/or less than 150
mg*cm2/cm and/or less than 100 mg*cm2/cm and/or less than 70
mg*cm2/cm and/or greater than 5 mg*cm2/cm and/or greater than 0
mg*cm2/cm and/or greater than 10 mg*cm2/cm and/or greater than
30 mg*cm2/cm and/or greater than 50 mg*cm2/cm.

[0081] In another example of the present invention as shown in FIG. 1, a
single-ply, through-air-dried, embossed fibrous structure exhibits a
Tensile Ratio of greater than 0.5 and/or greater than 1 and/or greater
than 1.33 and/or greater than 1.4 and/or greater than 1.5 and/or less
than 5 and/or less than 4 and/or less than 3 and/or less than 2 and a GM
Flexural Rigidity of less than 56 mg*cm2/cm and/or less than 54
mg*cm2/cm and/or less than 50 mg*cm2/cm and/or greater than 0
mg*cm2/cm and/or greater than 5 mg*cm2/cm and/or greater than
10 mg*cm2/cm.

[0082] In even another example of the present invention as shown in FIG.
1, a fibrous structure exhibits a Tensile Ratio of greater than 1.33
and/or greater than 1.4 and/or less than 1.75 and/or less than 1.6 and/or
less than 1.5 and a GM Flexural Rigidity of less than 70 mg*cm2/cm
and/or less than 60 mg*cm2/cm and/or less than 50 mg*cm2/cm
and/or greater than 0 mg*cm2/cm and/or greater than 5 mg*cm2/cm
and/or greater than 10 mg*cm2/cm.

[0083] In another example of the present invention as shown in FIG. 2, a
single-ply, embossed fibrous structure exhibits a Tensile Ratio of
greater than 0.5 and/or greater than 1 and/or greater than 1.33 and/or
less than 5 and/or less than 4 and/or less than 3 and/or less than 2 and
a GM Modulus of less than 935 g/cm and/or less than 930 g/cm and/or less
than 925 g/cm and/or greater than 0 g/cm and/or greater than 5 g/cm
and/or greater than 10 g/cm and/or greater than 30 g/cm and/or greater
than 50 g/cm.

[0084] In another example of the present invention as shown in FIG. 2, a
fibrous structure exhibits a Tensile Ratio of greater than 1.33 and/or
greater than 1.4 and/or less than 1.80 and/or less than 1.75 and/or less
than 1.6 and/or less than 1.5 and a GM Modulus of less than 935 g/cm
and/or less than 930 g/cm and/or less than 925 g/cm and/or greater than 0
g/cm and/or greater than 5 g/cm and/or greater than 10 g/cm and/or
greater than 30 g/cm and/or greater than 50 g/cm.

[0085] In another example of the present invention as shown in FIG. 3, a
single-ply, embossed fibrous structure exhibits a Tensile Ratio of
greater than 0.5 and/or greater than 1 and/or greater than 1.33 and/or
less than 5 and/or less than 4 and/or less than 3 and/or less than 2 and
a MD Modulus of less than 845 g/cm and/or less than 840 g/cm and/or less
than 835 g/cm and/or greater than 0 g/cm and/or greater than 5 g/cm
and/or greater than 10 g/cm and/or greater than 30 g/cm and/or greater
than 50 g/cm.

[0086] In still yet another example of the present invention as shown in
FIG. 3, a fibrous structure exhibits a Tensile Ratio of greater than 1.33
and/or greater than 1.4 and/or less than 1.80 and/or less than 1.75
and/or less than 1.6 and/or less than 1.5 and a MD Modulus of less than
845 g/cm and/or less than 840 g/cm and/or less than 835 g/cm and/or
greater than 0 g/cm and/or greater than 5 g/cm and/or greater than 10
g/cm and/or greater than 30 g/cm and/or greater than 50 g/cm.

[0087] In another example of the present invention as shown in FIG. 4, a
single-ply, embossed fibrous structure exhibits a Tensile Ratio of
greater than 1.2 and/or greater than 1.3 and/or greater than 1.33 and/or
less than 1.75 and/or less than 1.65 and/or less than 1.55 and a CD
Modulus of greater than 0 g/cm and/or greater than 10 g/cm and/or greater
than 100 g/cm and/or greater than 300 g/cm and/or greater than 500 g/cm
and/or less than 10,000 g/cm and/or less than 8,000 g/cm and/or less than
7,000 g/cm and/or less than 5,000 g/cm and/or less than 3,000 g/cm and/or
less than 2,000 g/cm and/or less than 1560 g/cm and/or less than 1,000
g/cm and/or less than 980 g/cm.

[0088] In even another example of the present invention as shown in FIG.
4, an embossed fibrous structure exhibits a Tensile Ratio of greater than
0.5 and/or greater than 1 and/or greater than 1.2 and/or greater than 1.3
and/or greater than 1.33 and/or less than 1.75 and/or less than 1.65
and/or less than 1.55 and a CD Modulus of greater than 0 g/cm and/or
greater than 10 g/cm and/or greater than 100 g/cm and/or greater than 500
g/cm and/or less than 1560 g/cm and/or less than 1500 g/cm and/or less
than 1250 g/cm and/or less than 1000 g/cm and/or less than 980 g/cm.

[0089] In still another example of the present invention as shown in FIG.
4, a fibrous structure that exhibits a Tensile Ratio of greater than 0.5
and/or greater than 1 and/or greater than 1.2 and/or greater than 1.3
and/or greater than 1.33 and/or less than 1.75 and/or less than 1.65
and/or less than 1.55 and a CD Modulus of greater than 0 g/cm and/or
greater than 10 g/cm and/or greater than 100 g/cm and/or greater than 500
g/cm and/or less than 980 g/cm and/or less than 975 g/cm and/or less than
970 g/cm and/or less than 960 g/cm.

[0090] Table 1 below shows the physical property values of some fibrous
structures in accordance with the present invention and commercially
available fibrous structures.

[0091] In even yet another example of the present invention, an embossed
fibrous structure comprises cellulosic pulp fibers. However, other
naturally-occurring and/or non-naturally occurring fibers and/or
filaments may be present in the fibrous structures of the present
invention.

[0092] In one example of the present invention, an embossed fibrous
structure comprises a through-air-dried fibrous structure. The embossed
fibrous structure may be creped or uncreped. In one example, the embossed
fibrous structure is a wet-laid fibrous structure.

[0093] In another example of the present invention, an embossed fibrous
structure may comprise one or more embossments.

[0094] The embossed fibrous structure may be incorporated into a single-
or multi-ply sanitary tissue product. The sanitary tissue product may be
in roll form where it is convolutedly wrapped about itself with or
without the employment of a core.

[0095] A non-limiting example of a fibrous structure in accordance with
the present invention is shown in FIGS. 5 and 6. FIGS. 5 and 6 show a
fibrous structure 10 comprising one or more linear elements 12. The
linear elements 12 are oriented in the machine or substantially the
machine direction on the surface 14 of the fibrous structure 10. In one
example, one or more of the linear elements 12 may exhibit a length L of
greater than about 4.5 mm and/or greater than about 6 mm and/or greater
than about 10 mm and/or greater than about 20 mm and/or greater than
about 30 mm and/or greater than about 45 mm and/or greater than about 60
mm and/or greater than about 75 mm and/or greater than about 90 mm. For
comparison, as shown in FIG. 7, a schematic representation of a
commercially available toilet tissue product 20 has a plurality of
substantially machine direction oriented linear elements 12 wherein the
longest linear element 12 present in the toilet tissue product 20
exhibits a length La of 4.3 mm or less. FIG. 8 is a micrograph of a
surface of a commercially available toilet tissue product 30 that
comprises substantially machine direction oriented linear elements 12
wherein the longest linear element 12 present in the toilet tissue
product 30 exhibits a length Lb of 4.3 mm or less.

[0096] In one example, the width W of one or more of the linear elements
12 is less than about 10 mm and/or less than about 7 mm and/or less than
about 5 mm and/or less than about 2 mm and/or less than about 1.7 mm
and/or less than about 1.5 mm to about 0 mm and/or to about 0.10 mm
and/or to about 0.20 mm. In another example, the linear element height of
one or more of the linear elements is greater than about 0.10 mm and/or
greater than about 0.50 mm and/or greater than about 0.75 mm and/or
greater than about 1 mm to about 4 mm and/or to about 3 mm and/or to
about 2.5 mm and/or to about 2 mm.

[0097] In another example, the fibrous structure of the present invention
exhibits a ratio of linear element height (in mm) to linear element width
(in mm) of greater than about 0.35 and/or greater than about 0.45 and/or
greater than about 0.5 and/or greater than about 0.75 and/or greater than
about 1.

[0098] One or more of the linear elements may exhibit a geometric mean of
linear element height by linear element of width of greater than about
0.25 mm2 and/or greater than about 0.35 mm2 and/or greater than
about 0.5 mm2 and/or greater than about 0.75 mm2.

[0099] As shown in FIGS. 5 and 6, the fibrous structure 10 may comprise a
plurality of substantially machine direction oriented linear elements 12
that are present on the fibrous structure 10 at a frequency of greater
than about 1 linear element/5 cm and/or greater than about 4 linear
elements/5 cm and/or greater than about 7 linear elements/5 cm and/or
greater than about 15 linear elements/5 cm and/or greater than about 20
linear elements/5 cm and/or greater than about 25 linear elements/5 cm
and/or greater than about 30 linear elements/5 cm up to about 50 linear
elements/5 cm and/or to about 40 linear elements/5 cm.

[0100] In another example of a fibrous structure according to the present
invention, the fibrous structure exhibits a ratio of a frequency of
linear elements (per cm) to the width (in cm) of one linear element of
greater than about 3 and/or greater than about 5 and/or greater than
about 7.

[0101] The linear elements of the present invention may be in any shape,
such as lines, zig-zag lines, serpentine lines. In one example, a linear
element does not intersect another linear element.

[0102] As shown in FIGS. 9 and 10, a fibrous structure 10a of the
present invention may comprise one or more linear elements 12a. The
linear elements 12a may be oriented on a surface 14a of a
fibrous structure 12a in any direction such as machine direction,
cross machine direction, substantially machine direction oriented,
substantially cross machine direction oriented. Two or more linear
elements may be oriented in different directions on the same surface of a
fibrous structure according to the present invention. In the case of
FIGS. 9 and 10, the linear elements 12a are oriented in the cross machine
direction. Even though the fibrous structure 10a comprises only two
linear elements 12a, it is within the scope of the present invention
for the fibrous structure 10' to comprise three or more linear elements
12a.

[0103] The dimensions (length, width and/or height) of the linear elements
of the present invention may vary from linear element to linear element
within a fibrous structure. As a result, the gap width between
neighboring linear elements may vary from one gap to another within a
fibrous structure.

[0104] In one example, the linear element may comprise an embossment. In
another example, the linear element may be an embossed linear element
rather than a linear element formed during a fibrous structure making
process.

[0105] In another example, a plurality of linear elements may be present
on a surface of a fibrous structure in a pattern such as in a corduroy
pattern.

[0106] In still another example, a surface of a fibrous structure may
comprise a discontinuous pattern of a plurality of linear elements
wherein at least one of the linear elements exhibits a linear element
length of greater than about 30 mm.

[0107] In yet another example, a surface of a fibrous structure comprises
at least one linear element that exhibits a width of less than about 10
mm and/or less than about 7 mm and/or less than about 5 mm and/or less
than about 3 mm and/or to about 0.01 mm and/or to about 0.1 mm and/or to
about 0.5 mm.

[0108] The linear elements may exhibit any suitable height known to those
of skill in the art. For example, a linear element may exhibit a height
of greater than about 0.10 mm and/or greater than about 0.20 mm and/or
greater than about 0.30 mm to about 3.60 mm and/or to about 2.75 mm
and/or to about 1.50 mm. A linear element's height is measured
irrespective of arrangement of a fibrous structure in a multi-ply fibrous
structure, for example, the linear element's height may extend inward
within the fibrous structure.

[0109] The fibrous structures of the present invention may comprise at
least one linear element that exhibits a height to width ratio of greater
than about 0.350 and/or greater than about 0.450 and/or greater than
about 0.500 and/or greater than about 0.600 and/or to about 3 and/or to
about 2 and/or to about 1.

[0110] In another example, a linear element on a surface of a fibrous
structure may exhibit a geometric mean of height by width of greater than
about 0.250 and/or greater than about 0.350 and/or greater than about
0.450 and/or to about 3 and/or to about 2 and/or to about 1.

[0111] The fibrous structures of the present invention may comprise linear
elements in any suitable frequency. For example, a surface of a fibrous
structure may comprises linear elements at a frequency of greater than
about 1 linear element/5 cm and/or greater than about 1 linear element/3
cm and/or greater than about 1 linear element/cm and/or greater than
about 3 linear elements/cm.

[0112] In one example, a fibrous structure comprises a plurality of linear
elements that are present on a surface of the fibrous structure at a
ratio of frequency of linear elements to width of at least one linear
element of greater than about 3 and/or greater than about 5 and/or
greater than about 7.

[0113] The fibrous structure of the present invention may comprise a
surface comprising a plurality of linear elements such that the ratio of
geometric mean of height by width of at least one linear element to
frequency of linear elements is greater than about 0.050 and/or greater
than about 0.750 and/or greater than about 0.900 and/or greater than
about 1 and/or greater than about 2 and/or up to about 20 and/or up to
about 15 and/or up to about 10.

[0114] In addition to one or more linear elements 12b, as shown in
FIG. 11, a fibrous structure 10b of the present invention may
further comprise one or more non-linear elements 16b. In one
example, a non-linear element 16b present on the surface 14b of
a fibrous structure 10b is water-resistant. In another example, a
non-linear element 16b present on the surface 14b of a fibrous
structure 10b comprises an embossment. When present on a surface of
a fibrous structure, a plurality of non-linear elements may be present in
a pattern. The pattern may comprise a geometric shape such as a polygon.
Non-limiting example of suitable polygons are selected from the group
consisting of: triangles, diamonds, trapezoids, parallelograms,
rhombuses, stars, pentagons, hexagons, octagons and mixtures thereof.

[0115] One or more of the fibrous structures of the present invention may
form a single- or multi-ply sanitary tissue product. In one example, as
shown in FIG. 12, a multi-ply sanitary tissue product 30 comprises a
first ply 32 and a second ply 34 wherein the first ply 32 comprises a
surface 14' comprising a plurality of linear elements 12', in this case
being oriented in the machine direction or substantially machine
direction oriented. The plies 32 and 34 are arranged such that the linear
elements 12' extend inward into the interior of the sanitary tissue
product 30 rather than outward.

[0116] In another example, as shown in FIG. 13, a multi-ply sanitary
tissue product 40 comprises a first ply 42 and a second ply 44 wherein
the first ply 42 comprises a surface 14d comprising a plurality of
linear elements 12d, in this case being oriented in the machine
direction or substantially machine direction oriented. The plies 42 and
44 are arranged such that the linear elements 12d extend outward
from the surface 14d of the sanitary tissue product 40 rather than
inward into the interior of the sanitary tissue product 40.

[0117] As shown in FIG. 14, a fibrous structure 10 of the present
invention may comprise a variety of different forms of linear elements
12e, alone or in combination, such as serpentines, dashes, MD and/or
CD oriented, and the like.

Methods for Making Fibrous Structures

[0118] The fibrous structures of the present invention may be made by any
suitable process known in the art. The method may be a fibrous structure
making process that uses a cylindrical dryer such as a Yankee (a
Yankee-process) or it may be a Yankeeless process as is used to make
substantially uniform density and/or uncreped fibrous structures.

[0119] The fibrous structure of the present invention may be made using a
molding member. A "molding member" is a structural element that can be
used as a support for an embryonic web comprising a plurality of
cellulosic fibers and a plurality of synthetic fibers, as well as a
forming unit to form, or "mold," a desired microscopical geometry of the
fibrous structure of the present invention. The molding member may
comprise any element that has fluid-permeable areas and the ability to
impart a microscopical three-dimensional pattern to the structure being
produced thereon, and includes, without limitation, single-layer and
multi-layer structures comprising a stationary plate, a belt, a woven
fabric (including Jacquard-type and the like woven patterns), a band, and
a roll. In one example, the molding member is a deflection member.

[0120] A "reinforcing element" is a desirable (but not necessary) element
in some embodiments of the molding member, serving primarily to provide
or facilitate integrity, stability, and durability of the molding member
comprising, for example, a resinous material. The reinforcing element can
be fluid-permeable or partially fluid-permeable, may have a variety of
embodiments and weave patterns, and may comprise a variety of materials,
such as, for example, a plurality of interwoven yarns (including
Jacquard-type and the like woven patterns), a felt, a plastic, other
suitable synthetic material, or any combination thereof.

[0121] In one example of a method for making a fibrous structure of the
present invention, the method comprises the step of contacting an
embryonic fibrous web with a deflection member (molding member) such that
at least one portion of the embryonic fibrous web is deflected
out-of-plane of another portion of the embryonic fibrous web. The phrase
"out-of-plane" as used herein means that the fibrous structure comprises
a protuberance, such as a dome, or a cavity that extends away from the
plane of the fibrous structure. The molding member may comprise a
through-air-drying fabric having its filaments arranged to produce linear
elements within the fibrous structures of the present invention and/or
the through-air-drying fabric or equivalent may comprise a resinous
framework that defines deflection conduits that allow portions of the
fibrous structure to deflect into the conduits thus forming linear
elements within the fibrous structures of the present invention. In
addition, a forming wire, such as a foraminous member may be arranged
such that linear elements within the fibrous structures of the present
invention are formed and/or like the through-air-drying fabric, the
foraminous member may comprise a resinous framework that defines
deflection conduits that allow portions of the fibrous structure to
deflect into the conduits thus forming linear elements within the fibrous
structures of the present invention.

[0122] In another example of a method for making a fibrous structure of
the present invention, the method comprises the steps of: [0123] (a)
providing a fibrous furnish comprising fibers; and [0124] (b) depositing
the fibrous furnish onto a deflection member such that at least one fiber
is deflected out-of-plane of the other fibers present on the deflection
member.

[0125] In still another example of a method for making a fibrous structure
of the present invention, the method comprises the steps of: [0126] (a)
providing a fibrous furnish comprising fibers; [0127] (b) depositing the
fibrous furnish onto a foraminous member to form an embryonic fibrous
web; [0128] (c) associating the embryonic fibrous web with a deflection
member such that at least one fiber is deflected out-of-plane of the
other fibers present in the embryonic fibrous web; and [0129] (d) drying
said embryonic fibrous web such that that the dried fibrous structure is
formed.

[0130] In another example of a method for making a fibrous structure of
the present invention, the method comprises the steps of:

[0131] (a) providing a fibrous furnish comprising fibers;

[0132] (b) depositing the fibrous furnish onto a first foraminous member
such that an embryonic fibrous web is formed;

[0133] (c) associating the embryonic web with a second foraminous member
which has one surface (the embryonic fibrous web-contacting surface)
comprising a macroscopically monoplanar network surface which is
continuous and patterned and which defines a first region of deflection
conduits and a second region of deflection conduits within the first
region of deflection conduits;

[0134] (d) deflecting the fibers in the embryonic fibrous web into the
deflection conduits and removing water from the embryonic web through the
deflection conduits so as to form an intermediate fibrous web under such
conditions that the deflection of fibers is initiated no later than the
time at which the water removal through the deflection conduits is
initiated; and

[0135] (e) optionally, drying the intermediate fibrous web; and

[0136] (f) optionally, foreshortening the intermediate fibrous web.

[0137] The fibrous structures of the present invention may be made by a
method wherein a fibrous furnish is applied to a first foraminous member
to produce an embryonic fibrous web.

[0138] The embryonic fibrous web may then come into contact with a second
foraminous member that comprises a deflection member to produce an
intermediate fibrous web that comprises a network surface and at least
one dome region. The intermediate fibrous web may then be further dried
to form a fibrous structure of the present invention.

[0139]FIG. 15 is a simplified, schematic representation of one example of
a continuous fibrous structure making process and machine useful in the
practice of the present invention.

[0140] As shown in FIG. 15, one example of a process and equipment,
represented as 50 for making a fibrous structure according to the present
invention comprises supplying an aqueous dispersion of fibers (a fibrous
furnish) to a headbox 52 which can be of any convenient design. From
headbox 52 the aqueous dispersion of fibers is delivered to a first
foraminous member 54 which is typically a Fourdrinier wire, to produce an
embryonic fibrous web 56.

[0141] The first foraminous member 54 may be supported by a breast roll 58
and a plurality of return rolls 60 of which only two are shown. The first
foraminous member 54 can be propelled in the direction indicated by
directional arrow 62 by a drive means, not shown. Optional auxiliary
units and/or devices commonly associated fibrous structure making
machines and with the first foraminous member 54, but not shown, include
forming boards, hydrofoils, vacuum boxes, tension rolls, support rolls,
wire cleaning showers, and the like.

[0142] After the aqueous dispersion of fibers is deposited onto the first
foraminous member 54, embryonic fibrous web 56 is formed, typically by
the removal of a portion of the aqueous dispersing medium by techniques
well known to those skilled in the art. Vacuum boxes, forming boards,
hydrofoils, and the like are useful in effecting water removal. The
embryonic fibrous web 56 may travel with the first foraminous member 54
about return roll 60 and is brought into contact with a deflection member
64, which may also be referred to as a second foraminous member. While in
contact with the deflection member 64, the embryonic fibrous web 56 will
be deflected, rearranged, and/or further dewatered.

[0143] The deflection member 64 may be in the form of an endless belt. In
this simplified representation, deflection member 64 passes around and
about deflection member return rolls 66 and impression nip roll 68 and
may travel in the direction indicated by directional arrow 70. Associated
with deflection member 64, but not shown, may be various support rolls,
other return rolls, cleaning means, drive means, and the like well known
to those skilled in the art that may be commonly used in fibrous
structure making machines.

[0144] Regardless of the physical form which the deflection member 64
takes, whether it is an endless belt as just discussed or some other
embodiment such as a stationary plate for use in making handsheets or a
rotating drum for use with other types of continuous processes, it must
have certain physical characteristics. For example, the deflection member
may take a variety of configurations such as belts, drums, flat plates,
and the like.

[0145] First, the deflection member 64 may be foraminous. That is to say,
it may possess continuous passages connecting its first surface 72 (or
"upper surface" or "working surface"; i.e. the surface with which the
embryonic fibrous web is associated, sometimes referred to as the
"embryonic fibrous web-contacting surface") with its second surface 74
(or "lower surface"; i.e., the surface with which the deflection member
return rolls are associated). In other words, the deflection member 64
may be constructed in such a manner that when water is caused to be
removed from the embryonic fibrous web 56, as by the application of
differential fluid pressure, such as by a vacuum box 76, and when the
water is removed from the embryonic fibrous web 56 in the direction of
the deflection member 64, the water can be discharged from the system
without having to again contact the embryonic fibrous web 56 in either
the liquid or the vapor state.

[0146] Second, the first surface 72 of the deflection member 64 may
comprise one or more ridges 78 as represented in one example in FIGS. 11
and 12. The ridges 78 may be made by any suitable material. For example,
a resin may be used to create the ridges 78. The ridges 78 may be
continuous, or essentially continuous. In one example, the ridges 78
exhibit a length of greater than about 30 mm. The ridges 78 may be
arranged to produce the fibrous structures of the present invention when
utilized in a suitable fibrous structure making process. The ridges 78
may be patterned. The ridges 78 may be present on the deflection member
64 at any suitable frequency to produce the fibrous structures of the
present invention. The ridges 78 may define within the deflection member
64 a plurality of deflection conduits 80. The deflection conduits 80 may
be discrete, isolated, deflection conduits.

[0147] The deflection conduits 80 of the deflection member 64 may be of
any size and shape or configuration so long at least one produces a
linear element in the fibrous structure produced thereby. The deflection
conduits 80 may repeat in a random pattern or in a uniform pattern.
Portions of the deflection member 64 may comprise deflection conduits 80
that repeat in a random pattern and other portions of the deflection
member 64 may comprise deflection conduits 80 that repeat in a uniform
pattern.

[0148] The ridges 78 of the deflection member 64 may be associated with a
belt, wire or other type of substrate. As shown in FIGS. 16 and 17, the
ridges 78 of the deflection member 64 is associated with a woven belt 82.
The woven belt 82 may be made by any suitable material, for example
polyester, known to those skilled in the art.

[0149] As shown in FIG. 17, a cross sectional view of a portion of the
deflection member 64 taken along line 17-17 of FIG. 16, the deflection
member 64 can be foraminous since the deflection conduits 80 extend
completely through the deflection member 64.

[0150] In one example, the deflection member of the present invention may
be an endless belt which can be constructed by, among other methods, a
method adapted from techniques used to make stencil screens. By "adapted"
it is meant that the broad, overall techniques of making stencil screens
are used, but improvements, refinements, and modifications as discussed
below are used to make member having significantly greater thickness than
the usual stencil screen.

[0151] Broadly, a foraminous member (such as a woven belt) is thoroughly
coated with a liquid photosensitive polymeric resin to a preselected
thickness. A mask or negative incorporating the pattern of the
preselected ridges is juxtaposed the liquid photosensitive resin; the
resin is then exposed to light of an appropriate wave length through the
mask. This exposure to light causes curing of the resin in the exposed
areas. Unexpected (and uncured) resin is removed from the system leaving
behind the cured resin forming the ridges defining within it a plurality
of deflection conduits.

[0152] In another example, the deflection member can be prepared using as
the foraminous member, such as a woven belt, of width and length suitable
for use on the chosen fibrous structure making machine. The ridges and
the deflection conduits are formed on this woven belt in a series of
sections of convenient dimensions in a batchwise manner, i.e. one section
at a time. Details of this non-limiting example of a process for
preparing the deflection member follow.

[0153] First, a planar forming table is supplied. This forming table is at
least as wide as the width of the foraminous woven element and is of any
convenient length. It is provided with means for securing a backing film
smoothly and tightly to its surface. Suitable means include provision for
the application of vacuum through the surface of the forming table, such
as a plurality of closely spaced orifices and tensioning means.

[0154] A relatively thin, flexible polymeric (such as polypropylene)
backing film is placed on the forming table and is secured thereto, as by
the application of vacuum or the use of tension. The backing film serves
to protect the surface of the forming table and to provide a smooth
surface from which the cured photosensitive resins will, later, be
readily released. This backing film will form no part of the completed
deflection member.

[0155] Either the backing film is of a color which absorbs activating
light or the backing film is at least semi-transparent and the surface of
the forming table absorbs activating light.

[0156] A thin film of adhesive, such as 8091 Crown Spray Heavy Duty
Adhesive made by Crown Industrial Products Co. of Hebron, Ill., is
applied to the exposed surface of the backing film or, alternatively, to
the knuckles of the woven belt. A section of the woven belt is then
placed in contact with the backing film where it is held in place by the
adhesive. The woven belt is under tension at the time it is adhered to
the backing film.

[0157] Next, the woven belt is coated with liquid photosensitive resin. As
used herein, "coated" means that the liquid photosensitive resin is
applied to the woven belt where it is carefully worked and manipulated to
insure that all the openings (interstices) in the woven belt are filled
with resin and that all of the filaments comprising the woven belt are
enclosed with the resin as completely as possible. Since the knuckles of
the woven belt are in contact with the backing film, it will not be
possible to completely encase the whole of each filament with
photosensitive resin. Sufficient additional liquid photosensitive resin
is applied to the woven belt to form a deflection member having a certain
preselected thickness. The deflection member can be from about 0.35 mm
(0.014 in.) to about 3.0 mm (0.150 in.) in overall thickness and the
ridges can be spaced from about 0.10 mm (0.004 in.) to about 2.54 mm
(0.100 in.) from the mean upper surface of the knuckles of the woven
belt. Any technique well known to those skilled in the art can be used to
control the thickness of the liquid photosensitive resin coating. For
example, shims of the appropriate thickness can be provided on either
side of the section of deflection member under construction; an excess
quantity of liquid photosensitive resin can be applied to the woven belt
between the shims; a straight edge resting on the shims and can then be
drawn across the surface of the liquid photosensitive resin thereby
removing excess material and forming a coating of a uniform thickness.

[0158] Suitable photosensitive resins can be readily selected from the
many available commercially. They are typically materials, usually
polymers, which cure or cross-link under the influence of activating
radiation, usually ultraviolet (UV) light. References containing more
information about liquid photosensitive resins include Green et al,
"Photocross-linkable Resin Systems," J. Macro. Sci-Revs. Macro. Chem,
C21(2), 187-273 (1981-82); Boyer, "A Review of Ultraviolet Curing
Technology," Tappi Paper Synthetics Conf. Proc., Sep. 25-27, 1978, pp
167-172; and Schmidle, "Ultraviolet Curable Flexible Coatings," J. of
Coated Fabrics, 8, 10-20 (July, 1978). All the preceding three references
are incorporated herein by reference. In one example, the ridges are made
from the Merigraph series of resins made by Hercules Incorporated of
Wilmington, Del.

[0159] Once the proper quantity (and thickness) of liquid photosensitive
resin is coated on the woven belt, a cover film is optionally applied to
the exposed surface of the resin. The cover film, which must be
transparent to light of activating wave length, serves primarily to
protect the mask from direct contact with the resin.

[0160] A mask (or negative) is placed directly on the optional cover film
or on the surface of the resin. This mask is formed of any suitable
material which can be used to shield or shade certain portions of the
liquid photosensitive resin from light while allowing the light to reach
other portions of the resin. The design or geometry preselected for the
ridges is, of course, reproduced in this mask in regions which allow the
transmission of light while the geometries preselected for the gross
foramina are in regions which are opaque to light.

[0161] A rigid member such as a glass cover plate is placed atop the mask
and serves to aid in maintaining the upper surface of the photosensitive
liquid resin in a planar configuration.

[0162] The liquid photosensitive resin is then exposed to light of the
appropriate wave length through the cover glass, the mask, and the cover
film in such a manner as to initiate the curing of the liquid
photosensitive resin in the exposed areas. It is important to note that
when the described procedure is followed, resin which would normally be
in a shadow cast by a filament, which is usually opaque to activating
light, is cured. Curing this particular small mass of resin aids in
making the bottom side of the deflection member planar and in isolating
one deflection conduit from another.

[0163] After exposure, the cover plate, the mask, and the cover film are
removed from the system. The resin is sufficiently cured in the exposed
areas to allow the woven belt along with the resin to be stripped from
the backing film.

[0164] Uncured resin is removed from the woven belt by any convenient
means such as vacuum removal and aqueous washing.

[0165] A section of the deflection member is now essentially in final
form. Depending upon the nature of the photosensitive resin and the
nature and amount of the radiation previously supplied to it, the
remaining, at least partially cured, photosensitive resin can be
subjected to further radiation in a post curing operation as required.

[0166] The backing film is stripped from the forming table and the process
is repeated with another section of the woven belt. Conveniently, the
woven belt is divided off into sections of essentially equal and
convenient lengths which are numbered serially along its length. Odd
numbered sections are sequentially processed to form sections of the
deflection member and then even numbered sections are sequentially
processed until the entire belt possesses the characteristics required of
the deflection member. The woven belt may be maintained under tension at
all times.

[0167] In the method of construction just described, the knuckles of the
woven belt actually form a portion of the bottom surface of the
deflection member. The woven belt can be physically spaced from the
bottom surface.

[0168] Multiple replications of the above described technique can be used
to construct deflection members having the more complex geometries.

[0169] The deflection member of the present invention may be made or
partially made according to U.S. Pat. No. 4,637,859, issued Jan. 20, 1987
to Trokhan.

[0170] As shown in FIG. 16, after the embryonic fibrous web 56 has been
associated with the deflection member 64, fibers within the embryonic
fibrous web 56 are deflected into the deflection conduits present in the
deflection member 64. In one example of this process step, there is
essentially no water removal from the embryonic fibrous web 56 through
the deflection conduits after the embryonic fibrous web 56 has been
associated with the deflection member 64 but prior to the deflecting of
the fibers into the deflection conduits. Further water removal from the
embryonic fibrous web 56 can occur during and/or after the time the
fibers are being deflected into the deflection conduits. Water removal
from the embryonic fibrous web 56 may continue until the consistency of
the embryonic fibrous web 56 associated with deflection member 64 is
increased to from about 25% to about 35%. Once this consistency of the
embryonic fibrous web 56 is achieved, then the embryonic fibrous web 56
is referred to as an intermediate fibrous web 84. During the process of
forming the embryonic fibrous web 56, sufficient water may be removed,
such as by a noncompressive process, from the embryonic fibrous web 56
before it becomes associated with the deflection member 64 so that the
consistency of the embryonic fibrous web 56 may be from about 10% to
about 30%.

[0171] While applicants decline to be bound by any particular theory of
operation, it appears that the deflection of the fibers in the embryonic
web and water removal from the embryonic web begin essentially
simultaneously. Embodiments can, however, be envisioned wherein
deflection and water removal are sequential operations. Under the
influence of the applied differential fluid pressure, for example, the
fibers may be deflected into the deflection conduit with an attendant
rearrangement of the fibers. Water removal may occur with a continued
rearrangement of fibers. Deflection of the fibers, and of the embryonic
fibrous web, may cause an apparent increase in surface area of the
embryonic fibrous web. Further, the rearrangement of fibers may appear to
cause a rearrangement in the spaces or capillaries existing between
and/or among fibers.

[0172] It is believed that the rearrangement of the fibers can take one of
two modes dependent on a number of factors such as, for example, fiber
length. The free ends of longer fibers can be merely bent in the space
defined by the deflection conduit while the opposite ends are restrained
in the region of the ridges. Shorter fibers, on the other hand, can
actually be transported from the region of the ridges into the deflection
conduit (The fibers in the deflection conduits will also be rearranged
relative to one another). Naturally, it is possible for both modes of
rearrangement to occur simultaneously.

[0173] As noted, water removal occurs both during and after deflection;
this water removal may result in a decrease in fiber mobility in the
embryonic fibrous web. This decrease in fiber mobility may tend to fix
and/or freeze the fibers in place after they have been deflected and
rearranged. Of course, the drying of the web in a later step in the
process of this invention serves to more firmly fix and/or freeze the
fibers in position.

[0174] Any convenient means conventionally known in the papermaking art
can be used to dry the intermediate fibrous web 84. Examples of such
suitable drying process include subjecting the intermediate fibrous web
84 to conventional and/or flow-through dryers and/or Yankee dryers.

[0175] In one example of a drying process, the intermediate fibrous web 84
in association with the deflection member 64 passes around the deflection
member return roll 66 and travels in the direction indicated by
directional arrow 70. The intermediate fibrous web 84 may first pass
through an optional predryer 86. This predryer 86 can be a conventional
flow-through dryer (hot air dryer) well known to those skilled in the
art. Optionally, the predryer 86 can be a so-called capillary dewatering
apparatus. In such an apparatus, the intermediate fibrous web 84 passes
over a sector of a cylinder having preferential-capillary-size pores
through its cylindrical-shaped porous cover. Optionally, the predryer 86
can be a combination capillary dewatering apparatus and flow-through
dryer. The quantity of water removed in the predryer 86 may be controlled
so that a predried fibrous web 88 exiting the predryer 86 has a
consistency of from about 30% to about 98%. The predried fibrous web 88,
which may still be associated with deflection member 64, may pass around
another deflection member return roll 66 and as it travels to an
impression nip roll 68. As the predried fibrous web 88 passes through the
nip formed between impression nip roll 68 and a surface of a Yankee dryer
90, the ridge pattern formed by the top surface 72 of deflection member
64 is impressed into the predried fibrous web 88 to form a linear element
imprinted fibrous web 92. The imprinted fibrous web 92 can then be
adhered to the surface of the Yankee dryer 90 where it can be dried to a
consistency of at least about 95%.

[0176] The imprinted fibrous web 92 can then be foreshortened by creping
the imprinted fibrous web 92 with a creping blade 94 to remove the
imprinted fibrous web 92 from the surface of the Yankee dryer 90
resulting in the production of a creped fibrous structure 96 in
accordance with the present invention. As used herein, foreshortening
refers to the reduction in length of a dry (having a consistency of at
least about 90% and/or at least about 95%) fibrous web which occurs when
energy is applied to the dry fibrous web in such a way that the length of
the fibrous web is reduced and the fibers in the fibrous web are
rearranged with an accompanying disruption of fiber-fiber bonds.
Foreshortening can be accomplished in any of several well-known ways. One
common method of foreshortening is creping. The creped fibrous structure
96 may be subjected to post processing steps such as calendaring, tuft
generating operations, and/or embossing and/or converting.

[0177] In addition to the Yankee fibrous structure making process/method,
the fibrous structures of the present invention may be made using a
Yankeeless fibrous structure making process/method. Such a process
oftentimes utilizes transfer fabrics to permit rush transfer of the
embryonic fibrous web prior to drying. The fibrous structures produced by
such a Yankeeless fibrous structure making process oftentimes a
substantially uniform density.

[0178] The molding member/deflection member of the present invention may
be utilized to imprint linear elements into a fibrous structure during a
through-air-drying operation.

[0179] However, such molding members/deflection members may also be
utilized as forming members upon which a fiber slurry is deposited.

[0180] In one example, the linear elements of the present invention may be
formed by a plurality of non-linear element, such as embossments and/or
protrusions and/or depressions formed by a molding member, that are
arranged in a line having an overall length of greater than about 4.5 mm
and/or greater than about 10 mm and/or greater than about 15 mm and/or
greater than about 25 mm and/or greater than about 30 mm.

[0181] In addition to imprinting linear elements into fibrous structures
during a fibrous structure making process/method, linear elements may be
created in a fibrous structure during a converting operation of a fibrous
structure. For example, linear elements may be imparted to a fibrous
structure by embossing linear elements into a fibrous structure.

Non-Limiting Example

[0182] The following Example illustrates a non-limiting example for a
preparation of a sanitary tissue product comprising a fibrous structure
according to the present invention on a pilot-scale Fourdrinier fibrous
structure making machine.

[0183] An aqueous slurry of eucalyptus (Aracruz Brazilian bleached
hardwood kraft pulp) pulp fibers is prepared at about 3% fiber by weight
using a conventional repulper, then transferred to the hardwood fiber
stock chest. The eucalyptus fiber slurry of the hardwood stock chest is
pumped through a stock pipe to a hardwood fan pump where the slurry
consistency is reduced from about 3% by fiber weight to about 0.15% by
fiber weight. The 0.15% eucalyptus slurry is then pumped and equally
distributed in the top and bottom chambers of a multi-layered,
three-chambered headbox of a Fourdrinier wet-laid papermaking machine.

[0184] Additionally, an aqueous slurry of NSK (Northern Softwood Kraft)
pulp fibers is prepared at about 3% fiber by weight using a conventional
repulper, then transferred to the softwood fiber stock chest. The NSK
fiber slurry of the softwood stock chest is pumped through a stock pipe
to be refined to a Canadian Standard Freeness (CSF) of about 630. The
refined NSK fiber slurry is then directed to the NSK fan pump where the
NSK slurry consistency is reduced from about 3% by fiber weight to about
0.15% by fiber weight. The 0.15% eucalyptus slurry is then directed and
distributed to the center chamber of a multi-layered, three-chambered
headbox of a Fourdrinier wet-laid papermaking machine.

[0185] The fibrous structure making machine has a layered headbox having a
top chamber, a center chamber, and a bottom chamber where the chambers
feed directly onto the forming wire. The eucalyptus fiber slurry of 0.15%
consistency is directed to the top headbox chamber and bottom headbox
chamber. The NSK fiber slurry is directed to the center headbox chamber.
All three fiber layers are delivered simultaneously in superposed
relation onto the Fourdrinier wire to form thereon a three-layer
embryonic web, of which about 25% of the top side is made up of the
eucalyptus fibers, about 25% is made of the eucalyptus fibers on the
bottom side and about 50% is made up of the NSK fibers in the center.
Dewatering occurs through the Fourdrinier wire and is assisted by a
deflector and wire table vacuum boxes. The Fourdrinier wire is of an
Asten Johnson 866A design. The speed of the Fourdrinier wire is about 750
feet per minute (fpm).

[0186] The embryonic wet web is transferred from the Fourdrinier wire, at
a fiber consistency of about 15% at the point of transfer, to a patterned
drying fabric. The speed of the patterned drying fabric is the same as
the speed of the Fourdrinier wire. The drying fabric is designed to yield
a pattern of low density pillow regions and high density knuckle regions.
This drying fabric is formed by casting an impervious resin surface onto
a fiber mesh supporting fabric. The supporting fabric is a 127×52
filament, dual layer mesh. The thickness of the resin cast is about 12
mils above the supporting fabric.

[0187] Further de-watering is accomplished by vacuum assisted drainage
until the web has a fiber consistency of about 20% to 30%.

[0188] While remaining in contact with the patterned drying fabric, the
web is pre-dried by air blow-through pre-dryers to a fiber consistency of
about 56% by weight.

[0189] After the pre-dryers, the semi-dry web is transferred to the Yankee
dryer and adhered to the surface of the Yankee dryer with a sprayed
creping adhesive. The creping adhesive is an aqueous dispersion with the
actives consisting of about 22% polyvinyl alcohol, about 11% CREPETROL
A3025, and about 67% CREPETROL R6390. CREPETROL A3025 and CREPETROL R6390
are commercially available from Hercules Incorporated of Wilmington, Del.
The creping adhesive is delivered to the Yankee surface at a rate of
about 0.15% adhesive solids based on the dry weight of the web. The fiber
consistency is increased to about 97% before the web is dry-creped from
the Yankee with a doctor blade.

[0190] The doctor blade has a bevel angle of about 25 degrees and is
positioned with respect to the Yankee dryer to provide an impact angle of
about 81 degrees. The Yankee dryer is operated at a temperature of about
350° F. (177° C.) and a speed of about 750 fpm. The fibrous
structure is wound in a roll using a surface driven reel drum having a
surface speed of about 673 fpm. The fibrous structure may be subsequently
converted into a one-ply sanitary tissue product.

[0191] The fibrous structure is then converted into a sanitary tissue
product by loading the roll of fibrous structure into an unwind stand.
The line speed is 800 ft/min. The fibrous structure is unwound and
transported to a steam header where steam is applied to the fibrous
structure at a rate of 327-383 g/min. The steam pressure is 29-38 psi and
the steam temperature is 270-282° F. The fibrous structure is then
transported to an emboss stand where the fibrous structure is strained to
form the emboss pattern in the fibrous structure. The embossed fibrous
structure is then transported to a winder where it is wound onto a core
to form a log. The log of fibrous structure is then transported to a log
saw where the log is cut into finished sanitary tissue product rolls. The
sanitary tissue product is soft, flexible and absorbent.

Test Methods

[0192] Unless otherwise specified, all tests described herein including
those described under the Definitions section and the following test
methods are conducted on samples that have been conditioned in a
conditioned room at a temperature of 73° F.±4° F. (about
23° C.±2.2° C.) and a relative humidity of 50%±10%
for 2 hours prior to the test. If the sample is in roll form, remove the
first 35 to about 50 inches of the sample by unwinding and tearing off
via the closest perforation line, if one is present, and discard before
testing the sample. All plastic and paper board packaging materials must
be carefully removed from the paper samples prior to testing. Discard any
damaged product. All tests are conducted in such conditioned room.

Flexural Rigidity Test Method

[0193] This test is performed on 1 inch×6 inch (2.54 cm×15.24
cm) strips of a fibrous structure sample. A Cantilever Bending Tester
such as described in ASTM Standard D 1388 (Model 5010, Instrument
Marketing Services, Fairfield, N.J.) is used and operated at a ramp angle
of 41.5±0.5° and a sample slide speed of 0.5±0.2 in/second
(1.3±0.5 cm/second). A minimum of n=16 tests are performed on each
sample from n=8 sample strips.

[0194] No fibrous structure sample which is creased, bent, folded,
perforated, or in any other way weakened should ever be tested using this
test. A non-creased, non-bent, non-folded, non-perforated, and
non-weakened in any other way fibrous structure sample should be used for
testing under this test.

[0195] From one fibrous structure sample of about 4 inch×6 inch
(10.16 cm×15.24 cm), carefully cut using a 1 inch (2.54 cm) JDC
Cutter (available from Thwing-Albert Instrument Company, Philadelphia,
Pa.) four (4) 1 inch (2.54 cm) wide by 6 inch (15.24 cm) long strips of
the fibrous structure in the MD direction. From a second fibrous
structure sample from the same sample set, carefully cut four (4) 1 inch
(2.54 cm) wide by 6 inch (15.24 cm) long strips of the fibrous structure
in the CD direction. It is important that the cut be exactly
perpendicular to the long dimension of the strip. In cutting
non-laminated two-ply fibrous structure strips, the strips should be cut
individually. The strip should also be free of wrinkles or excessive
mechanical manipulation which can impact flexibility. Mark the direction
very lightly on one end of the strip, keeping the same surface of the
sample up for all strips. Later, the strips will be turned over for
testing, thus it is important that one surface of the strip be clearly
identified, however, it makes no difference which surface of the sample
is designated as the upper surface.

[0196] Using other portions of the fibrous structure (not the cut strips),
determine the basis weight of the fibrous structure sample in lbs/3000
ft2 and the caliper of the fibrous structure in mils (thousandths of
an inch) using the standard procedures disclosed herein. Place the
Cantilever Bending Tester level on a bench or table that is relatively
free of vibration, excessive heat and most importantly air drafts. Adjust
the platform of the Tester to horizontal as indicated by the leveling
bubble and verify that the ramp angle is at 41.5±0.5°. Remove
the sample slide bar from the top of the platform of the Tester. Place
one of the strips on the horizontal platform using care to align the
strip parallel with the movable sample slide. Align the strip exactly
even with the vertical edge of the Tester wherein the angular ramp is
attached or where the zero mark line is scribed on the Tester. Carefully
place the sample slide bar back on top of the sample strip in the Tester.
The sample slide bar must be carefully placed so that the strip is not
wrinkled or moved from its initial position.

[0197] Move the strip and movable sample slide at a rate of approximately
0.5±0.2 in/second (1.3±0.5 cm/second) toward the end of the Tester
to which the angular ramp is attached. This can be accomplished with
either a manual or automatic Tester. Ensure that no slippage between the
strip and movable sample slide occurs. As the sample slide bar and strip
project over the edge of the Tester, the strip will begin to bend, or
drape downward. Stop moving the sample slide bar the instant the leading
edge of the strip falls level with the ramp edge. Read and record the
overhang length from the linear scale to the nearest 0.5 mm. Record the
distance the sample slide bar has moved in cm as overhang length. This
test sequence is performed a total of eight (8) times for each fibrous
structure in each direction (MD and CD). The first four strips are tested
with the upper surface as the fibrous structure was cut facing up. The
last four strips are inverted so that the upper surface as the fibrous
structure was cut is facing down as the strip is placed on the horizontal
platform of the Tester.

[0198] The average overhang length is determined by averaging the sixteen
(16) readings obtained on a fibrous structure.

wherein W is the basis weight of the fibrous structure in lbs/3000
ft2; C is the bending length (MD or CD or Total) in cm; and the
constant 0.1629 is used to convert the basis weight from English to
metric units. The results are expressed in mg*cm2/cm (or
alternatively mg*cm). GM Flexural Rigidity=Square root of (MD Flexural
Rigidity×CD Flexural Rigidity)

Basis Weight Test Method

[0199] Basis weight of a fibrous structure sample is measured by selecting
twelve (12) usable units (also referred to as sheets) of the fibrous
structure and making two stacks of six (6) usable units each. Perforation
must be aligned on the same side when stacking the usable units. A
precision cutter is used to cut each stack into exactly 8.89
cm×8.89 cm (3.5 in.×3.5 in.) squares. The two stacks of cut
squares are combined to make a basis weight pad of twelve (12) squares
thick. The basis weight pad is then weighed on a top loading balance with
a minimum resolution of 0.01 g. The top loading balance must be protected
from air drafts and other disturbances using a draft shield. Weights are
recorded when the readings on the top loading balance become constant.
The Basis Weight is calculated as follows:

[0200] Caliper of a fibrous structure is measured by cutting five (5)
samples of fibrous structure such that each cut sample is larger in size
than a load foot loading surface of a VIR Electronic Thickness Tester
Model II available from Thwing-Albert Instrument Company, Philadelphia,
Pa. Typically, the load foot loading surface has a circular surface area
of about 3.14 int. The sample is confined between a horizontal flat
surface and the load foot loading surface. The load foot loading surface
applies a confining pressure to the sample of 15.5 g/cm2. The
caliper of each sample is the resulting gap between the flat surface and
the load foot loading surface. The caliper is calculated as the average
caliper of the five samples. The result is reported in millimeters (mm).

Elongation, Tensile Strength, TEA and Modulus Test Methods

[0201] Remove five (5) strips of four (4) usable units (also referred to
as sheets) of fibrous structures and stack one on top of the other to
form a long stack with the perforations between the sheets coincident.
Identify sheets 1 and 3 for machine direction tensile measurements and
sheets 2 and 4 for cross direction tensile measurements. Next, cut
through the perforation line using a paper cutter (JDC-1-10 or JDC-1-12
with safety shield from Thwing-Albert Instrument Co. of Philadelphia,
Pa.) to make 4 separate stacks. Make sure stacks 1 and 3 are still
identified for machine direction testing and stacks 2 and 4 are
identified for cross direction testing.

[0203] For the actual measurement of the elongation, tensile strength, TEA
and modulus, use a Thwing-Albert Intelect II Standard Tensile Tester
(Thwing-Albert Instrument Co. of Philadelphia, Pa.). Insert the flat face
clamps into the unit and calibrate the tester according to the
instructions given in the operation manual of the Thwing-Albert Intelect
II. Set the instrument crosshead speed to 4.00 in/min (10.16 cm/min) and
the 1st and 2nd gauge lengths to 2.00 inches (5.08 cm). The break
sensitivity is set to 20.0 grams and the sample width is set to 1.00 inch
(2.54 cm) and the sample thickness is set to 0.3937 inch (1 cm). The
energy units are set to TEA and the tangent modulus (Modulus) trap
setting is set to 38.1 g.

[0204] Take one of the fibrous structure sample strips and place one end
of it in one clamp of the tensile tester. Place the other end of the
fibrous structure sample strip in the other clamp. Make sure the long
dimension of the fibrous structure sample strip is running parallel to
the sides of the tensile tester. Also make sure the fibrous structure
sample strips are not overhanging to the either side of the two clamps.
In addition, the pressure of each of the clamps must be in full contact
with the fibrous structure sample strip.

[0205] After inserting the fibrous structure sample strip into the two
clamps, the instrument tension can be monitored. If it shows a value of 5
grams or more, the fibrous structure sample strip is too taut.
Conversely, if a period of 2-3 seconds passes after starting the test
before any value is recorded, the fibrous structure sample strip is too
slack.

[0206] Start the tensile tester as described in the tensile tester
instrument manual. The test is complete after the crosshead automatically
returns to its initial starting position. When the test is complete, read
and record the following with units of measure:

[0207] Peak Load Tensile (Tensile Strength) (g/in)

[0208] Peak Elongation (Elongation) (%)

[0209] Peak TEA (TEA) (in-g/in2)

[0210] Tangent Modulus (Modulus) (at 15 g/cm)

[0211] Test each of the samples in the same manner, recording the above
measured values from each test.

[0213] Fibrous structure samples for each condition to be tested are cut
to a size appropriate for testing (minimum sample size 4.5
inches×4.5 inches), a minimum of five (5) samples for each
condition to be tested are prepared.

[0214] A burst tester (Burst Tester Intelect-II-STD Tensile Test
Instrument, Cat. No. 1451-24PGB available from Thwing-Albert Instrument
Co., Philadelphia, Pa.) is set up according to the manufacturer's
instructions and the following conditions: Speed: 12.7 centimeters per
minute; Break Sensitivity: 20 grams; and Peak Load: 2000 grams. The load
cell is calibrated according to the expected burst strength.

[0215] A fibrous structure sample to be tested is clamped and held between
the annular clamps of the burst tester and is subjected to increasing
force that is applied by a 0.625 inch diameter, polished stainless steel
ball upon operation of the burst tester according to the manufacturer's
instructions. The burst strength is that force that causes the sample to
fail.

[0216] The burst strength for each fibrous structure sample is recorded.
An average and a standard deviation for the burst strength for each
condition is calculated.

[0217] The Dry Burst is reported as the average and standard deviation for
each condition to the nearest gram.

[0218] The length of a linear element in a fibrous structure and/or the
length of a linear element forming component in a molding member is
measured by image scaling of a light microscopy image of a sample of
fibrous structure.

[0219] A light microscopy image of a sample to be analyzed such as a
fibrous structure or a molding member is obtained with a representative
scale associated with the image. The images is saved as a *.tiff file on
a computer. Once the image is saved, SmartSketch, version 05.00.35.14
software made by Intergraph Corporation of Huntsville, Ala., is opened.
Once the software is opened and running on the computer, the user clicks
on "New" from the "File" drop-down panel. Next, "Normal" is selected.
"Properties" is then selected from the "File" drop-down panel. Under the
"Units" tab, "mm" (millimeters) is chosen as the unit of measure and
"0.123" as the precision of the measurement. Next, "Dimension" is
selected from the "Format" drop-down panel. Click the "Units" tab and
ensure that the "Units" and "Unit Labels" read "mm" and that the
"Round-Off" is set at "0.123." Next, the "rectangle" shape from the
selection panel is selected and dragged into the sheet area. Highlight
the top horizontal line of the rectangle and set the length to the
corresponding scale indicated light microscopy image. This will set the
width of the rectangle to the scale required for sizing the light
microscopy image. Now that the rectangle has been sized for the light
microscopy image, highlight the top horizontal line and delete the line.
Highlight the left and right vertical lines and the bottom horizontal
line and select "Group". This keeps each of the line segments grouped at
the width dimension ("mm") selected earlier. With the group highlighted,
drop the "line width" panel down and type in "0.01 mm." The scaled line
segment group is now ready to use for scaling the light microscopy image
can be confirmed by right-clicking on the "dimension between", then
clicking on the two vertical line segments.

[0220] To insert the light microscopy image, click on the "Image" from the
"insert" drop-down panel. The image type is preferably a *.tiff format.
Select the light microscopy image to be inserted from the saved file,
then click on the sheet to place the light microscopy image. Click on the
right bottom corner of the image and drag the corner diagonally from
bottom-right to top-left. This will ensure that the image's aspect ratio
will not be modified. Using the "Zoom In" feature, click on the image
until the light microscopy image scale and the scale group line segments
can be seen. Move the scale group segment over the light microscopy image
scale. Increase or decrease the light microscopy image size as needed
until the light microscopy image scale and the scale group line segments
are equal. Once the light microscopy image scale and the scale group line
segments are visible, the object(s) depicted in the light microscopy
image can be measured using "line symbols" (located in the selection
panel on the right) positioned in a parallel fashion and the "Distance
Between" feature. For length and width measurements, a top view of a
fibrous structure and/or molding member is used as the light microscopy
image. For a height measurement, a side or cross sectional view of the
fibrous structure and/or molding member is used as the light microscopy
image.

[0221] The dimensions and values disclosed herein are not to be understood
as being strictly limited to the exact numerical values recited. Instead,
unless otherwise specified, each such dimension is intended to mean both
the recited value and a functionally equivalent range surrounding that
value. For example, a dimension disclosed as "40 mm" is intended to mean
"about 40 mm."

[0222] Every document cited herein, including any cross referenced or
related patent or application, is hereby incorporated herein by reference
in its entirety unless expressly excluded or otherwise limited. The
citation of any document is not an admission that it is prior art with
respect to any invention disclosed or claimed herein or that it alone, or
in any combination with any other reference or references, teaches,
suggests or discloses any such invention. Further, to the extent that any
meaning or definition of a term in this document conflicts with any
meaning or definition of the same term in a document incorporated by
reference, the meaning or definition assigned to that term in this
document shall govern.

[0223] While particular embodiments of the present invention have been
illustrated and described, it would be obvious to those skilled in the
art that various other changes and modifications can be made without
departing from the spirit and scope of the invention. It is therefore
intended to cover in the appended claims all such changes and
modifications that are within the scope of this invention.

Patent applications by Ashley Lynn Kuntz, Cincinnati, OH US

Patent applications by Jeremy Howard Nugent, Liberty Township, OH US

Patent applications by John Allen Manifold, Milan, IN US

Patent applications by Joshua Thomas Fung, Cincinnati, OH US

Patent applications by Kathryn Christian Kien, Cincinnati, OH US

Patent applications by Kevin Mitchell Wiwi, West Chester, OH US

Patent applications in class Including variation in thickness

Patent applications in all subclasses Including variation in thickness